Method for manufacturing sealing element and sealing element

Abstract

The present disclosure relates to a method for producing a seal, which is a method for continuously producing a seal, comprising: a filling step of filling a mold with an ultraviolet curable seal composition; and an irradiation step for irradiating the ultraviolet curable sealing material composition with ultraviolet light, the mold having ultraviolet light permeability. According to the present disclosure, it is possible to provide a method for manufacturing a sealing material and a sealing material which have a short manufacturing time and are not susceptible to heat generation during curing.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a sealing component, and further relates to a sealing component. Background Art

[0002] Japanese Patent Application Laid-Open No. 2017-177720 discloses a method for producing a seal by filling a heat-crosslinkable rubber composition into a mold and performing hot press molding.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2017-177720 Summary of the Invention

[0006] Problems to be solved by the invention

[0007] In the seal manufacturing method described in Japanese Patent Application Laid-Open No. 2017-177720, crosslinking the heat-crosslinkable rubber composition takes a long time, making it difficult to shorten the time required to manufacture the seal. Furthermore, hot press molding generates a large amount of heat, resulting in increased carbon dioxide emissions.

[0008] The present invention provides a method for manufacturing a sealing member which has a short manufacturing time and is less likely to generate heat during curing, and a sealing member.

[0009] Solutions for solving problems

[0010] The present invention provides the following method for manufacturing a seal and the seal.

[0011] [1] A method for manufacturing a sealant, which is a method for continuously manufacturing a sealant, comprising: a filling step of filling a mold with an ultraviolet curable sealant composition; and an irradiation step of irradiating the ultraviolet curable sealant composition with ultraviolet light, wherein the mold is ultraviolet-transmissive.

[0012] [2] The method for manufacturing a seal according to [1], wherein the mold is formed of a tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer.

[0013] [3] The method for producing a seal according to [1] or [2], wherein the ultraviolet curable seal composition contains an ultraviolet curable resin component and a photopolymerization initiator.

[0014] [4] The method for producing a seal according to any one of [1] to [3], wherein the ultraviolet curable resin component contains a polyolefin resin, an acrylic resin, or an epoxy resin.

[0015] [5] The method for manufacturing a seal according to any one of [1] to [4], further comprising at least one step selected from the group consisting of a mold preparation step, a demolding step, an inspection step, a cleaning step, a release agent coating step, and a sealing step.

[0016] [6] The method for manufacturing a seal according to any one of [1] to [5], comprising the step of disposing one selected from the group consisting of a film, a plate material, and a molded article.

[0017] [7] The method for manufacturing a seal according to any one of [1] to [6], wherein the method for continuously manufacturing the seal is at least one selected from the group consisting of a linear method, a multi-line method, and a rotational method.

[0018] [8] The method for manufacturing a seal according to any one of [1] to [7], wherein a plurality of steps are integrated into one step.

[0019] [9] The method for manufacturing a seal according to any one of [1] to [8], wherein a plurality of steps are performed in parallel.

[0020]

[10] A sealant comprising a cured product of an ultraviolet curable sealant composition.

[0021]

[11] The seal according to

[10] , wherein the ultraviolet curable seal composition contains an acrylic resin or an epoxy resin.

[0022] Effects of the Invention

[0023] According to the present invention, a method for manufacturing a sealing member and a sealing member can be provided, which can shorten the manufacturing time and is less likely to generate heat during curing. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a flowchart showing a method for manufacturing a seal according to the present invention.

[0025] Figure 2 This is a diagram schematically illustrating a method for continuously manufacturing seals.

[0026] Figure 3 This is a perspective view schematically showing a manufacturing apparatus used in the method for manufacturing a seal according to the present invention.

[0027] Figure 4 This is a perspective view schematically showing a mold used in the method for producing a seal according to the present invention.

[0028] Figure 5 This is a cross-sectional view schematically showing a filling device and a mold used in the method for producing a seal according to the present invention.

[0029] Figure 6 This is a schematic diagram showing a cross section of the seal of the present invention. DETAILED DESCRIPTION

[0030] Below, we will refer to the attached Figure 1 While the embodiments of the present invention are described below, the present invention is not limited to the following embodiments. In all the following drawings, the scales of the components have been appropriately adjusted for ease of understanding, and the scales of the components shown in the drawings are not necessarily consistent with the scales of the actual components.

[0031] <Seal Manufacturing Method>

[0032] The method for producing a sealant of the present invention is a method for continuously producing a sealant, comprising: a filling step of filling a mold with an ultraviolet curable sealant composition; and an irradiation step of irradiating the ultraviolet curable sealant composition with ultraviolet light, wherein the mold has ultraviolet transparency.

[0033] In the method for manufacturing a seal of the present invention, since the ultraviolet curable sealant composition is cured by irradiation with ultraviolet rays, the sealant manufacturing time is shorter and heat generation is less likely to occur compared to the case where a heat-crosslinkable rubber composition is subjected to heat crosslinking. Furthermore, in the method for manufacturing a seal of the present invention, since the mold has ultraviolet permeability, the ultraviolet curable sealant composition is irradiated with ultraviolet rays through the mold, so that the ultraviolet curable sealant composition can be cured while being filled in the mold. Therefore, although the method for manufacturing a seal of the present invention uses an ultraviolet curable sealant composition, it is possible to manufacture seals of various shapes and has a tendency to have excellent molding processability.

[0034] Figure 1 The manufacturing method of the seal shown includes: a filling step (S20) of filling a mold with an ultraviolet curable sealant composition; and an irradiation step (S30) of irradiating the ultraviolet curable sealant composition with ultraviolet rays. The manufacturing method of the seal may further include other steps in addition to the above. As other steps, for example, there can be listed: a mold preparation step, a demoulding step, an inspection step, a cleaning step, a release agent coating step, a packaging step, etc. The manufacturing method of the seal may include a step of configuring one selected from the group consisting of a film, a plate and a molded object in the mold preparation step. As Figure 1As shown, the manufacturing method of the seal may further include: a mold preparation step (S10) of preparing (assembling) a mold, a demolding step (S40) of removing the seal from the mold, an inspection step (S50) of inspecting the removed seal, a packaging step (S60) of packaging the seal, a cleaning step (S70) of cleaning the mold returned to the mold preparation step (S10), a release agent coating step (S80) of coating a release agent on the cleaned mold, etc.

[0035] The method for manufacturing a sealing member can continuously perform a filling process and an irradiation process. Figure 2 The mold preparation step (S10) to the release agent application step (S80) can be performed continuously. After the release step (S40), the mold can be returned to the mold preparation step (S10), allowing the above steps to be repeated continuously. Using multiple molds allows for the production of many seals in a short period of time.

[0036] The method for continuously manufacturing seals is not particularly limited, and examples thereof include: a method in which the above steps are performed in series while the mold is conveyed linearly (hereinafter referred to as a linear method); a method in which multiple linear methods are performed in parallel (hereinafter referred to as a multi-line method); a method in which the above steps are performed while the mold is conveyed concentrically (hereinafter referred to as a rotary method), etc. Furthermore, multiple steps may be combined into a single step or performed in parallel.

[0037] Figure 2 3 is a diagram illustrating a method for continuously manufacturing seals, in which the arrows indicate the conveying direction of the mold. Figure 2 The method shown in (a) is a linear method in which steps a1, a2, a3 and a4 are performed continuously in this order, the mold is recovered in step a4 (eg, demolding step), and the mold is returned to step a1 (eg, mold preparation step). Figure 2 The method shown in (b) is a linear method in which processes a1, a2, a3 and a4 are performed continuously in the order of processes a2, multiple processes a2 are set in parallel, the mold is recovered in process a4 (for example, demolding process), and the mold is returned to process a1 (for example, mold preparation process). Figure 2 The method shown in (c) is a rotation method in which the steps a1, a2, a3 and a4 are carried out in the order of steps a2, and in step a2, the mold is transported and processed in the order of steps 1 to 8 in a concentric circle. Figure 3 As shown in (c), for example, in step a3 (such as demolding step), the product can be taken out from the mold and the mold can be returned to step a1 (such as mold preparation step), and the product continues to be transported to the subsequent step a4 (such as inspection step, etc.).

[0038] Regarding the manufacturing method of the seal, for example, the time from the mold preparation step through the filling step and the irradiation step to the removal of the seal in the demolding step (production tact time) can be, for example, less than 60 seconds, preferably less than 50 seconds, more preferably less than 40 seconds, further preferably less than 30 seconds, particularly preferably less than 20 seconds, and extremely preferably less than 10 seconds.

[0039] The seal manufacturing method can use a seal manufacturing apparatus. The seal manufacturing apparatus can be configured such that multiple apparatuses for performing the above-mentioned steps are arranged linearly, any one or all of the multiple apparatuses can be arranged in parallel, multiple apparatuses can be arranged concentrically, or these arrangements can be combined.

[0040] Figure 3 A device for manufacturing a linear seal is shown. Figure 3 The manufacturing method of the seal of the present invention is described in detail with reference to the manufacturing device 10 of the seal shown in the figure. The conveying device 11, the mold 12, the filling device 13, and the ultraviolet irradiation device 14 of the manufacturing device 10 are arranged in a straight line. In the mold preparation process (S10), the mold 12 is set on the conveying device 11 and is transported to the filling process (S20). The ultraviolet curable sealant composition is filled into the mold 12 by the filling device 13. Then, in the irradiation process (S30), ultraviolet rays are irradiated. After curing, the mold 12 is removed in the demolding process (S40), thereby manufacturing the seal 15. The mold 12 can be returned to the mold preparation process.

[0041] As the conveying device 11 , for example, a belt conveyor, a free-flow conveyor, a linear conveyor module, conveying rollers, a conveying arm, etc. can be used.

[0042] In the mold preparation process, the mold 12 is prepared. As shown in the figure, the mold 12 can be assembled using an upper mold 12a and a lower mold 12b. The upper mold 12a and the lower mold 12b can be fixed to each other using screws or the like after being assembled. Figure 3 As shown, when the mold 12 is composed of an upper mold 12a and a lower mold 12b, a substrate 16 forming a seal can be arranged between the upper mold 12a and the lower mold 12b. The substrate 16 can be, for example, one selected from the group consisting of a film, a plate, and a molded object. The substrate 16 can be, for example, a metal plate, preferably stainless steel (SUS). The substrate 16 can be included in the product together with the seal.

[0043] Regarding the ultraviolet transmittance of mold 12, the light transmittance at a wavelength of 365 nm can be, for example, 80% or greater. From the perspective of the curability of the ultraviolet-curable sealant composition, it is preferably 90% or greater, more preferably 95% or greater, and generally 100% or less. Mold 12 may be ultraviolet-transmissive throughout, or only in the portion necessary for curing the ultraviolet-curable sealant composition.

[0044] The mold 12 can be formed of a material having ultraviolet transparency. For example, the entire mold 12 can be formed of a material having ultraviolet transparency, or only the part having ultraviolet transparency of the mold 12 can be formed of a material having ultraviolet transparency, and the other parts can be made of a material that does not have ultraviolet transparency. As materials having ultraviolet transparency, for example, there can be listed: glass, quartz, polyester resins, polycarbonate resins, acrylic resins, polycarbonate resins, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymers (PFA), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), tetrafluoroethylene-ethylene copolymers (ETFE), polychlorotrifluoroethylene (ECTFE), cycloolefin polymers (COP), etc. Among them, from the viewpoint of operability and transparency, PFA is preferred. Materials having ultraviolet transparency can be used alone or in combination of two or more.

[0045] The mold 12 may have a hollow portion (cavity) according to the shape of the seal to be manufactured. Figure 4 In the embodiment, the cavity portion can be formed by the upper mold 12a and the substrate 16. When ultraviolet rays are irradiated from above the mold, the upper mold only needs to be transparent to ultraviolet rays. The upper mold 12a is preferably formed of PFA.

[0046] The mold 12 may include a filling nozzle insert portion into which a filling nozzle for filling the ultraviolet curable sealant composition is inserted. The shape of the filling nozzle insert portion is preferably a shape that can be engaged with the filling nozzle. The mold 12 may also include a flow channel portion. The filling nozzle insert portion may be connected to the flow channel portion, and the flow channel portion may be connected to the cavity portion.

[0047] The mold 12 can have one or more filling nozzle insertion parts, a cavity part, and a flow channel part. When there are multiple filling nozzle insertion parts, the ultraviolet curable sealant composition can be filled from multiple positions, thereby shortening the time of the filling process. The filling nozzle insertion part can be configured to be directly connected to the cavity part, or it can be configured to be connected to the cavity part via the flow channel part. The flow channel part is the path through which the ultraviolet curable sealant composition flows to the cavity part. Figure 4 This is a schematic diagram of the mold viewed from obliquely above. Figure 5The mold 20 shown includes a cavity 21 and a runner 22. The runner 22 is connected to the cavity 21. A filling nozzle insert (not shown) may be connected to the runner 22.

[0048] In the filling step, a filling device 13 can be used to fill the mold 12 with the UV-curable sealant composition. The filling device 13 preferably includes a filling nozzle for filling the mold 12 with the UV-curable sealant composition. The filling device 13 may include one or more filling nozzles. The tip of the filling nozzle may be truncated cone-shaped.

[0049] When the ultraviolet curable sealing composition is filled into the mold 12 , the mold 12 may be placed in a vacuum state before filling in order to facilitate the flow of the ultraviolet curable sealing composition into the mold 12 .

[0050] By installing a pressure sensor in the runner section 22 of the mold 12 and obtaining data on the relationship between the flow and pressure of the ultraviolet curable sealant composition in advance, the completion of filling can be managed using the pressure of the runner section 22. Alternatively, the completion of filling can be managed using the filling time instead of the pressure.

[0051] Figure 5 (a) and (b) show the cross-section of the filling device and the mold. Figure 5 In (a), the filling device 30 has a filling nozzle 31 and a flow channel 38. The mold 32 is composed of an upper mold 36, a base plate 39, and a lower mold 37. The upper mold 36 has a filling nozzle insertion portion 33, a flow channel 34, and a cavity 35. The filling nozzle 31 has a truncated cone shape. Figure 3 As shown in (b), the mold 32 is filled with the UV-curable sealant composition by assembling the upper mold 36, the substrate 39, and the lower mold 37, inserting the filling nozzle 31 into the filling nozzle insertion portion 33, supplying the UV-curable sealant composition to the filling nozzle 31 via the flow channel 38 from the direction of the arrow in the figure, and filling the cavity 35 via the flow channel 34. The filling nozzle 31 can be inserted to the deepest part of the filling nozzle insertion portion 33.

[0052] The ultraviolet irradiation device 14 may include a light source such as a metal halide lamp or LED. Ultraviolet irradiation conditions such as ultraviolet irradiation time, ultraviolet irradiation intensity, and integrated light quantity can be adjusted according to the curing speed of the ultraviolet curable sealant composition.

[0053] In the demoulding process, the seal is removed from the mold. Figure 6In the process, the seal 15 is removed from the mold while being formed on the substrate 16. To facilitate removal of the seal from the mold, the surface of the portion forming the mold cavity may be subjected to a release treatment before filling with the UV-curable sealant composition. Examples of the release treatment include application of a release agent and pre-fluorination treatment of the mold surface.

[0054] The ultraviolet curable sealing composition is a composition that is cured by ultraviolet irradiation. The ultraviolet curable sealing composition may contain an ultraviolet curable resin component and a photopolymerization initiator.

[0055] Examples of the UV-curable resin component include rubber resins, polyolefin resins, acrylic resins, epoxy resins, silicone resins, urethane resins, vinyl alkyl ether resins, polyvinyl pyrrolidone resins, polyacrylamide resins, and cellulose resins. The UV-curable resin component may include polyolefin resins, acrylic resins, or epoxy resins. These cured products have crosslinking points and can exhibit rubber elasticity.

[0056] Examples of rubber resins include isoprene rubber, butadiene rubber, styrene-butadiene rubber, chloroprene rubber, nitrile rubber, ethylene propylene rubber, chlorosulfonated polyethylene rubber, acrylic rubber, fluororubber, epichlorohydrin rubber, urethane rubber, and silicone rubber. Examples of polyolefin resins include polyisobutylene. Commercially available UV-curable sealant compositions containing polyolefin resins include Three Bond 3178 (manufactured by Three Bond Co., Ltd.).

[0057] The content of the ultraviolet-curable resin component in the solid content of the ultraviolet-curable sealant composition can be, for example, 50% by mass or more, preferably 50% by mass or more, more preferably 60% by mass or more, further preferably 70% by mass or more, particularly preferably 80% by mass or more, and extremely preferably 90% by mass or more. The content of the ultraviolet-curable resin component in the solid content of the ultraviolet-curable sealant composition can be, for example, 99% by mass or less, or 98% by mass or less.

[0058] As a photopolymerization initiator, a photocationic polymerization initiator, a photoradical polymerization initiator, etc. are mentioned, for example.

[0059] The content of the photopolymerization initiator relative to 100 parts by mass of the ultraviolet curable resin component may be, for example, 0.001 parts by mass to 10 parts by mass, preferably 0.005 parts by mass to 10 parts by mass, and more preferably 0.01 parts by mass to 10 parts by mass.

[0060] The ultraviolet curable sealant composition may further contain a crosslinking agent, other resin components, additives, fillers, and the like.

[0061] The viscosity of the UV-curable sealant composition can be, for example, 500 Pa·s or less. From the perspective of filling performance, it is preferably 300 Pa·s or less, and more preferably 200 Pa·s or less. The viscosity of the UV-curable sealant composition can be measured, for example, using a B-type viscometer. The viscosity during filling can be reduced by heating.

[0062] Seals

[0063] The seal of the present invention comprises a cured product of an ultraviolet curable sealant composition. The above description is applicable to ultraviolet curable sealant compositions. The seal of the present invention is manufactured by the above-mentioned manufacturing method. The seal manufactured by the above-mentioned manufacturing method is cured in a mold, and therefore, unlike a seal in which the ultraviolet curable sealant composition is directly applied to a substrate and cured, it can have a portion with a square cross-sectional shape in the thickness direction. The square can be a square or a rectangle. From the perspective of normal physical properties, the ultraviolet curable sealant composition preferably comprises a rubber resin, an acrylic resin or an epoxy resin.

[0064] The shape of the seal as viewed in the thickness direction may be any shape, such as circular, square, annular, or frame-shaped. The overall size of the seal as viewed in the thickness direction may be, for example, 50 mm or more and 1000 mm or less, 100 mm or more and 700 mm or less, or 200 mm or more and 500 mm or less. If the seal is annular or frame-shaped, the width as viewed in the thickness direction may be, for example, 0.1 mm or more and 4 mm or less, or 0.5 mm or more and 2 mm or less.

[0065] The thickness of the seal may be, for example, 0.01 mm to 10 mm, 0.05 mm to 5 mm, or 0.1 mm to 1 mm.

[0066] Figure 6 FIG. 2 shows a cross section of a portion of a frame-shaped seal having a square cross section in the thickness direction. ​ As shown, the seal 100 may have a portion having a length T in the thickness direction (thickness) greater than a length L in a direction perpendicular to the thickness direction. The ratio of T to L (T / L) may be, for example, 1.0 or more and 2.0 or less.

[0067] The seal of the present application can be manufactured by the above-mentioned manufacturing method of a seal. According to the above-mentioned manufacturing method of a seal, the ultraviolet-curable seal composition can be cured in a normal state filled into a mold, and thus the seal including a cured product of the ultraviolet-curable seal composition can have a portion having a square cross-sectional shape in the thickness direction.

[0068] The seal of the present application can have a runner or a parting line generated along a joint of a mold-constituting member.

[0069] The use of the seal of the present application is not particularly limited, and can be all uses in which the seal is used, such as uses for vehicles, airplanes, ships, internal combustion engines, manufacturing devices, plants, medical supplies, buildings, semiconductors, foods, batteries, and the like. In addition, the seal of the present application can also be combined with a mold, a resin part, various sheets to form an integral molded product, a composite product, or the like.

[0070] [Examples]

[0071] Hereinafter, the present application will be further described in detail by examples. Unless otherwise specified, "%" and "parts" in the examples are mass % and mass parts.

[0072] [Preparation of the ultraviolet-curable seal composition]

[0073] The ultraviolet-curable seal composition was prepared by mixing and stirring polyisobutylene and a photopolymerization initiator.

[0074] <Example 1>

[0075] In the mold preparation step, a SUS plate was arranged between an upper mold and a lower mold formed of a PFA resin to prepare a mold. The upper mold had a filling nozzle insertion portion, a runner portion, and a gate portion. A filling nozzle of a filling device was inserted into the filling nozzle insertion portion of the mold transported to the filling step by a belt conveyor. The ultraviolet-curable seal composition was filled into the hollow portion of the mold from the filling nozzle. Next, the filling nozzle was removed from the mold. Then, the mold filled with the ultraviolet-curable seal composition was transported to the irradiation step and was irradiated with ultraviolet rays by an ultraviolet irradiation device having a metal halide lamp to cure the ultraviolet-curable seal composition. Then, the seal was removed from the mold together with the SUS plate in the demolding step. The seal was in a frame shape, had a thickness of 0.1 mm, and had an overall size of 200 mm x 500 mm when viewed in the thickness direction and a width of 2 mm.

[0076] Explanation of Reference Numerals

[0077] 10: Manufacturing device; 11: Conveying device; 12: Mold; 13: Filling device; 14: Ultraviolet irradiation device; 15: Sealing member; 16: Substrate; 20: Mold; 21: Cavity portion; 22, 34, 38: Flow path portion; 30: Filling device; 31: Filling nozzle; 32: Mold; 33: Filling nozzle insertion portion; 35: Cavity portion; 36: Upper mold; 37: Lower mold; 100: Sealing member.

Claims

1. A method for manufacturing a sealing member, which is a method for continuously manufacturing a sealing member, comprising: a filling step of filling the mold with the ultraviolet curable sealant composition; as well as an irradiation step of irradiating the ultraviolet curable sealant composition with ultraviolet rays, The mold is ultraviolet-transmissive.

2. The method for manufacturing a seal according to claim 1, wherein: The mold is formed of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer.

3. The method for manufacturing a seal according to claim 1, wherein: The ultraviolet curable sealant composition includes an ultraviolet curable resin component and a photopolymerization initiator.

4. The method for manufacturing a seal according to claim 1, wherein: The ultraviolet curable resin component includes a polyolefin resin, an acrylic resin, or an epoxy resin.

5. The method for manufacturing a seal according to claim 1, wherein: Further including: At least one step selected from the group consisting of a mold preparation step, a mold release step, an inspection step, a cleaning step, a mold release agent application step, and a sealing step.

6. The method for manufacturing a seal according to claim 1, wherein: include: A step of disposing one selected from the group consisting of a film, a plate, and a molded article.

7. The method for manufacturing a seal according to claim 1, wherein: The method of continuously manufacturing the seal is at least one selected from the group consisting of a linear method, a multi-line method, and a rotational method.

8. The method for manufacturing a seal according to claim 1, wherein: Integrate multiple processes into one process.

9. The method for manufacturing a seal according to claim 1, wherein: Multiple processes are performed in parallel.

10. A sealant comprising a cured product of an ultraviolet curable sealant composition.

11. The seal according to claim 10, wherein The ultraviolet curable sealant composition includes a polyolefin resin, an acrylic resin, or an epoxy resin.

Images